Ink jet printer cartridge manufacturing method and apparatus

Abstract

The invention provides an improved ink jet cartridge for an ink jet printer and a method for making the improved ink jet cartridge. The ink jet cartridge includes a substantially inflexible frame having at least one pressure port, the frame having at least one peripheral edge. At least one malleable web is provided having a first side and a second side the first side being attached to the peripheral edge of the frame defining a substantially closed cavity. The malleable web is conformed to the cavity by applying a subatmospheric pressure to the cavity before, after or while heating the malleable web in order to substantially conform the web to the cavity thereby creating a variable volume cavity having a substantially predictable pressure/volume relationship. A biasing element is disposed adjacent the first or second side of the malleable web for biasing the web relative to the cavity. Because the malleable web is conformed to the cavity with heat and differential pressure, ink flow in and out of the ink cartridge is more predictable and the pressure in the ink cartridge is easier to maintained at a desired level thereby improving print quality.

What is claimed is:  
     
       1. A method for manufacturing a pressure control device for an ink jet cartridge, the method comprising the steps of: 
       providing a substantially inflexible frame having at least one pressure port, the frame having at least one peripheral edge;  
       providing at least one malleable web, having a first side and a second side;  
       attaching the first side of the malleable web to the peripheral edge of the frame, thereby defining a substantially closed cavity;  
       applying a subatmospheric pressure to the cavity through the pressure port before, after or while heating the malleable web to a temperature sufficient to soften and mold the web so that the web substantially conforms to the cavity, thereby providing a cavity having a variable volume; and  
       providing a biasing means adjacent the first or second side of the conformed web to bias the web relative to the cavity.  
     
     
       2. The method of claim  1 , wherein the malleable web comprises a polymeric laminate material. 
     
     
       3. The method of claim  1 , wherein the malleable web conformed to the cavity by heating the web using a heating device selected from the group consisting of an infrared lamp, a heat lamp or a hot air producing device. 
     
     
       4. The method of claim  1 , wherein the biasing means is adjacent the first side of the malleable web. 
     
     
       5. The method of claim  1  wherein the biasing means is adjacent the second side of the malleable web. 
     
     
       6. The method of claim  1 , wherein the biasing means is selected from the group consisting of leaf springs, coil springs and resilient foam. 
     
     
       7. The method of claim  1 , wherein the malleable web is comprised of laminar layers of material selected from the group of polymeric materials consisting of polyvinylidene chloride, polyethylene, polypropylene, polyamide, and polyethylene teraplithalate, and combinations of two or more of the foregoing, as well as metallized films made from the foregoing polymeric materials. 
     
     
       8. The method of claim  1  further comprising attaching a thermal masking device to the peripheral edge of the frame prior to applying heat to the web. 
     
     
       9. An ink jet pen for use in an ink jet printer, the pen including an ink jet cartridge body and ink jet cartridge attached to the cartridge body, the ink jet cartridge containing ink and comprising: 
       a substantially inflexible frame having at least one pressure port, the frame having at least one peripheral edge;  
       at least one malleable web having a first side and a second side, the first side being attached to the peripheral edge of the frame thereby defining a substantially closed cavity, wherein the malleable web is substantially conformed to the cavity by applying a subatmospheric pressure to the cavity before, after or while heating the malleable web, thereby providing a cavity having a variable volume, and  
       biasing means adjacent the first or second side of the malleable web for biasing the web relative to the cavity.  
     
     
       10. The ink jet pen of claim  9 , wherein the ink jet cartridge body is comprised of material selected from the group consisting of metal, polymeric materials, glass and ceramic materials. 
     
     
       11. The ink jet pen of claim  9 , wherein the ink is contained within the variable volume cavity. 
     
     
       12. The ink jet pen of claim  9 , wherein the ink is external to the variable volume cavity. 
     
     
       13. The ink jet pen of claim  9 , wherein the malleable web comprises a polymeric laminate. 
     
     
       14. The ink jet pen of claim  9 , wherein the biasing means is adjacent the first side of the malleable web. 
     
     
       15. The ink jet pen of claim  9 , wherein the biasing means is adjacent the second side of the malleable web. 
     
     
       16. The ink jet pen of claim  9 , wherein the biasing means is selected from the group consisting of leaf springs, coil springs and resilient foam. 
     
     
       17. The ink jet pen of claim  9 , wherein the malleable web is comprised of laminar layers of material selected from the group of polymeric materials consisting of polyvinylidene chloride, polyethylene, polypropylene, polyamide, and polyethylene teraplithalate, and combinations of two or more of the foregoing, as well as metallized films made from the foregoing polymeric materials. 
     
     
       18. The ink jet pen of claim  9  wherein the at least one malleable web provides the cavity as having substantially similar ink pressure-to-volume relationships upon filling and draining the cavity, the pressure-to-volume relationships defined by a first curve representing ink pressure versus volume during filling of the cavity, and a second curve representing ink pressure versus volume during draining of the cavity, where the first and second curves have substantially the same slope at corresponding volumes points. 
     
     
       19. The ink jet pen of claim  9  wherein the at least one malleable web provides the cavity as having substantially similar ink pressure-to-volume relationships upon filling and draining the cavity, the pressure-to-volume relationships defined by a first curve representing ink pressure versus volume during filling of the cavity, and a second curve representing ink pressure versus volume during draining of the cavity, where a difference between pressure values at corresponding volume points in the first and second curves is substantially constant. 
     
     
       20. The ink jet pen of claim  19  wherein the difference between pressure values at corresponding volume points in the first and second curves is no greater than about 0.9 centimeter negative water column. 
     
     
       21. An ink jet cartridge for an ink jet printer, the ink jet cartridge comprising: 
       a substantially inflexible frame having at least one pressure port, the frame having at least one peripheral edge;  
       at least one malleable web having a first side and a second side, the first side being attached to the peripheral edge of the frame defining a substantially closed cavity, wherein the malleable web is conformed to the cavity by applying a subatmospheric pressure to the cavity before, after or while heating the malleable web in order to substantially conform the web to the cavity thereby creating a variable volume cavity,  
       biasing means adjacent the first or second side of the malleable web for biasing the web relative to the cavity, and  
       ink in the ink jet cartridge for printing on a print media.  
     
     
       22. The ink jet cartridge of claim  21 , wherein the ink is contained within the variable volume cavity. 
     
     
       23. The ink jet cartridge of claim  21 , wherein the ink is external to the variable volume cavity. 
     
     
       24. The ink jet cartridge of claim  21 , wherein the malleable web comprises a polymeric laminate. 
     
     
       25. The ink jet cartridge of claim  21 , wherein the biasing means is adjacent the first side of the malleable web. 
     
     
       26. The ink jet cartridge of claim  21 , wherein the biasing means is adjacent the second side of the malleable web. 
     
     
       27. The ink jet cartridge of claim  21 , wherein the biasing means is selected from the group consisting of a leaf springs, coil springs and resilient foam. 
     
     
       28. The ink jet cartridge of claim  21 , wherein the malleable web is comprised of laminar layers of material selected from the group of polymeric materials consisting of polyvinylidene chloride, polyethylene, polypropylene, polyamide, and polyethylene teraplithalate, and combinations of two or more of the foregoing, as well as metallized films made from the foregoing polymeric materials. 
     
     
       29. The ink jet cartridge of claim  21 , wherein the ink jet cartridge body is comprised of material selected from the group consisting of metal, polymeric materials, glass and ceramic materials.